sinamics engineering manual v6 0 internal en

SINAMICS - Low Voltage Engineering Manual SINAMICS G130, G150, S120 Chassis, S120 Cabinet Modules, S150

Version 6.0 x July 2010 Supplement to Catalogs D 11 x 2011 and D 21.3 x 2011

SINAMICS Drives

www.siemens.com s

For internal use only

Literary reference The following title by Jens Weidauer

Electrical Drive Systems *

Fundamentals Design Applications Solutions

offers a wide-ranging, clear and comprehensible overview of modern drive systems.

The book covers all aspects of modern electrical drive systems from the viewpoint of the user. On the one hand, it is

aimed at practicians who want to understand, design, use and maintain electrical drives. On the other, it will be a useful reference document for skilled workers, technicians, engineers and students who wish to gain a broad general understanding of electrical drive technology. The author explains the fundamentals of electrical drives and their design, and goes on to describe different applications as well as complex automation solutions. He presents the entire spectrum of drive solutions with the relevant core applications in each case. He gives special attention to the practice of combining multiple drives into drive systems and to the integration of drives into automated systems.

In simple, plain language and illustrated by numerous graphics, complex relationships are explained in a clear and coherent manner. The author consciously avoids the use of complicated mathematical formulae, concentrating instead on providing plain, comprehensible explanations of operating principles and relationships. The book is designed to help readers to understand electrical drive systems in their entirety and to solve the drive-related problems they may encounter in their daily working lives.

Contents

1 An overview of electrical drives 2 Fundamentals of mechanical engineering 3 Fundamentals of electrotechnical engineering 4 Constant-speed and variable-speed drives with DC motor 5 Constant-speed and variable-speed drives with asynchronous motor 6 Servo drives 7 Stepper drives 8 An overview of electrical drive systems 9 Fieldbuses for electrical drives 10 Process control with electrical drives 11 Motion control with electrical drives 12 EMC in electrical drive systems 13 Designing electrical drive systems 14 Troubleshooting on electrical drive systems ISBN 978-3-89578-308-1 Published by: Siemens Aktiengesellschaft, Berlin and Munich Publishing house: Publicis Corporate Publishing, Erlangen www.publicis-erlangen.de/books

* English translation not yet available. Only currently available in German

Approved for internal use only. SINAMICS Engineering Manual July 2010 Please note separate customer version! Siemens AG

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s Foreword

List of Contents

SINAMICS Low Voltage Engineering Manual

Fundamental Principles and System Description

Version 6.0 July 2010 Supplement to Catalogs D11 2011 and D21.3 2011

EMC Installation Guideline

For internal use only

General Engineering Information for SINAMICS

Converter Chassis Units SINAMICS G130

Converter Cabinet Units SINAMICS G150

General Information about Built-in and Cabinet Units SINAMICS S120

General Information about Modular Cabinet Units SINAMICS S120 Cabinet Modules

Converter Cabinet Units SINAMICS S150

Description of Options for Cabinet Units SINAMICS G150, S120 Cabinet Modules, S150

General Information about Drive Dimensioning

Disclaimer We have checked that the contents of this document correspond to the hardware and software described. However, as deviations cannot be totally excluded, we are unable to guarantee complete consistency. The information given in this publication is reviewed at regular intervals and any corrections that might be necessary are made in the subsequent editions. Subject to change without prior notice. Siemens AG 2010

Motors

Foreword Engineering Information

SINAMICS Engineering Manual July 2010 Approved for internal use only. Siemens AG Please note separate customer version!

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Foreword

Engineering Information


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To all users of the engineering manual!

This engineering manual is supplementary to the SINAMICS Catalogs D 11 2011 and D 21.3 2011 and is designed to provide additional support to users of SINAMICS converters. It contains a general analysis of the fundamental principles of variable-speed electric drives as well as detailed system descriptions and specific information about individual converter types. All information in this engineering manual refers to the upgraded device variants equipped with the following hardware and software:

Power unit with Control Interface Module CIM (order number ending in 3, e.g. 6SL3310-1GE38-4AA3) CU320-2 Control Unit Firmware version 4.3 or higher

The description focuses on typical applications of the Large Drives Division, i.e. drives in the higher power range with units in Chassis and Cabinet format operating in vector control mode (drive objects of vector type). Drives in the lower power range with units in Blocksize or Booksize format operating in servo control mode (drive objects of servo type) are both treated as marginal subjects only. This SINAMICS engineering manual is divided into different chapters. The initial chapters focus on the physical fundamentals of electrical variable-speed drives, general system descriptions and electromagnetic compatibility. They are giving general information about the configuration of devices in the SINAMICS range. The following chapters engineering of converter types SINAMICS G130, G150, S120 Built-in units, S120 Cabinet Modules and S150 deal with questions related to specific unit types in more detail than the chapter on fundamental principles. This engineering manual can and should only be viewed as a supplement to Catalogs D 11 2011, D 21.3 2011 and PM 21 2011 / "SINAMICS S120 drive system". The document does not therefore contain any ordering data. It is available only as an electronic document in PDF format and only in English and German. The information it contains is aimed at technically qualified and trained personnel. The configuring engineer is responsible for assessing whether the information provided is sufficiently comprehensive for the application in question and, therefore, assumes overall responsibility for the whole drive or the system. Please note that this engineering manual in its entirety is a planning document intended and approved solely for SIEMENS internal use and must not be passed on to external customers. A separate customer version of the engineering manual is provided for customer use. This can be downloaded via the Siemens INTRANET link specified below and it is also stored as a PDF file on the CD-ROMs included in SINAMICS Catalogs D 11 2011 and D 21.3 2011. These CD-ROMs also include the dimension drawings of the SINAMICS units described in this engineering manual.

EMC warning information The SINAMICS converter systems G130, G150, S120 Chassis units, S120 Cabinet Modules and S150 are not designed to be connected to public networks (first environment). RFI suppression of these converter systems is designed for industrial networks (second environment) in accordance with the EMC product standard EN 61800-3 for variable-speed drives. If the converter systems are connected to public networks (first environment) electromagnetic interference can occur. With additional measures (e.g. EMC-filters) the converter systems can also be connected to public networks

Availability: For downloading in PDF format from Siemens INTRANET http://support.automation.siemens.com/WW/view/en/22756643

Responsible for technical content: I DT LD P PMC Product Management / Technical Consulting Dr. Netzold mailto:[email protected]

Editor: I DT LD P S MK Marketing Kommunikation Mr. Rder mailto:[email protected]

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List of Contents

1 Fundamental Principles and System Description............................................................................. 14 1.1 Operating principle of SINAMICS converters ....................................................................................................... 14

1.1.1 General operating principle ................................................................................................................. 14 1.1.2 Pulse modulation method.................................................................................................................... 14 1.1.2.1 Generation of a variable voltage by pulse-width modulation ............................................................... 15 1.1.2.2 Maximum attainable output voltage with space vector modulation SVM ............................................. 17 1.1.2.3 Maximum attainable output voltage with pulse-edge modulation PEM................................................ 17 1.1.3 The pulse frequency and its influence on key system properties ........................................................ 19 1.1.4 Open-loop and closed-loop control modes.......................................................................................... 21 1.1.4.1 General information about speed adjustment...................................................................................... 21 1.1.4.2 V/f control modes ................................................................................................................................ 22 1.1.4.3 Field-oriented control modes ............................................................................................................... 23 1.1.4.4 A comparison of the key features of open-loop and closed-loop control modes.................................. 25 1.1.5 Power ratings of SINAMICS converters and inverters / Definition of the output power ....................... 26

1.2 Supply systems and supply system types ............................................................................................................ 28 1.2.1 General ............................................................................................................................................... 28 1.2.2 Connection of converters to the supply system and protection of converters...................................... 29 1.2.3 Short Circuit Current Rating SCCR ..................................................................................................... 30 1.2.4 Connection of converters to grounded systems (TN or TT)................................................................. 31 1.2.5 Connection of converters to non-grounded systems (IT)..................................................................... 31 1.2.6 Connection of converters to supply systems with different short-circuit powers .................................. 33 1.2.7 Supply voltage variations and supply voltage dips .............................................................................. 35 1.2.8 Behaviour of SINAMICS converters during supply voltage variations and dips................................... 36 1.2.9 Permissible harmonics on the supply voltage...................................................................................... 42

1.3 Transformers........................................................................................................................................................ 43 1.3.1 Unit transformers................................................................................................................................. 43 1.3.2 Transformer types ............................................................................................................................... 45 1.3.3 Features of standard transformers and converter transformers .......................................................... 46 1.3.4 Three-winding transformers................................................................................................................. 48

1.4 Harmonic effects on the supply system................................................................................................................ 51 1.4.1 General ............................................................................................................................................... 51 1.4.2 Harmonic currents of 6-pulse rectifier circuits..................................................................................... 53 1.4.2.1 SINAMICS G130, G150, S120 Basic Infeed and S120 Smart Infeed in motor operation .................... 53 1.4.2.2 SINAMICS S120 Smart Infeed in regenerative operation.................................................................... 55 1.4.3 Harmonic currents of 6-pulse rectifier circuits with Line Harmonics Filter .......................................... 56 1.4.4 Harmonic currents of 12-pulse rectifier circuits................................................................................... 58 1.4.5 Harmonic currents and harmonic voltages of Active Infeeds (AFE technology) .................................. 59 1.4.6 Standards and permissible harmonics ................................................................................................ 61

1.5 Line-side reactors and filters ................................................................................................................................ 65 1.5.1 Line reactors (line commutating reactors) ........................................................................................... 65 1.5.2 Line Harmonics Filters (LHF and LHF compact) ................................................................................. 66 1.5.3 Line filters (radio frequency interference (RFI) suppression filter or EMC filter) .................................. 71 1.5.3.1 General information and standards ..................................................................................................... 71 1.5.3.2 Line filters for the "first" environment (residential) and "second" environment (industrial) ................... 73 1.5.3.3 Operating principle of line filters .......................................................................................................... 74

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1.5.3.4 Magnitude of leakage or interference currents .................................................................................... 74 1.5.3.5 EMC-compliant installation .................................................................................................................. 75

1.6 SINAMICS Infeeds and their properties................................................................................................................ 78 1.6.1 Basic Infeed......................................................................................................................................... 78 1.6.2 Smart Infeed ........................................................................................................................................ 80 1.6.3 Active Infeed........................................................................................................................................ 82 1.6.4 Comparison of the properties of the different SINAMICS Infeeds........................................................ 86 1.6.5 Permissible combinations of Infeeds (mixed operation on a common DC link) ................................... 88 1.6.5.1 Mixed operation of Basic Infeeds and Smart Infeeds........................................................................... 88 1.6.5.2 Mixed operation of Basic Infeeds and Active Infeeds .......................................................................... 93 1.6.5.3 Mixed operation of Smart Infeeds and Active Infeeds.......................................................................... 93 1.6.6 Redundant line supply concepts .......................................................................................................... 94 1.6.7 Permissible total cable length for S120 Infeed Modules feeding multi-motor drives .......................... 100

1.7 SINAMICS Inverters or Motor Modules .............................................................................................................. 101 1.7.1 Operating principle and properties..................................................................................................... 101 1.7.2 Multi-motor drives with several Motor Modules at a common DC busbar .......................................... 102 1.7.2.1 Connection of Motor Modules to the DC busbar, fuse protection and precharging............................ 102 1.7.2.2 Arrangement of Motor Modules along the DC busbar........................................................................ 104 1.7.2.3 Permissible dimensions and topologies of the DC busbar................................................................. 107 1.7.2.4 Maximum power rating of drive configurations at a common DC busbar........................................... 109

1.8 SINAMICS braking units (Braking Modules and braking resistors)..................................................................... 111 1.9 Effects of using fast-switching power components (IGBTs)................................................................................ 112

1.9.1 Increased current load on the inverter output as a result of long motor cables.................................. 112 1.9.2 Increased voltage stress on the motor winding as a result of long motor cables ............................... 114 1.9.3 Bearing currents caused by steep voltage edges on the motor ......................................................... 118 1.9.3.1 Measures for reducing bearing currents ............................................................................................ 119 1.9.3.1.1 EMC-compliant installation for optimized equipotential bonding in the drive system .................... 120 1.9.3.1.2 Insulated bearing at the non-drive end (NDE) of the motor........................................................... 124 1.9.3.1.3 Other measures ............................................................................................................................ 124 1.9.3.2 Brief overview of the different types of bearing currents .................................................................... 125

1.10 Motor-side reactors and filters .......................................................................................................................... 126 1.10.1 Motor reactors.................................................................................................................................... 126 1.10.1.1 Reduction of the voltage rate-of-rise dv/dt at the motor terminals................................................. 126 1.10.1.2 Reduction of additional current peaks when long motor cables are used ..................................... 126 1.10.1.3 Permissible motor cable lengths with motor reactor(s) for single- and multi-motor drives ............ 127 1.10.1.4 Supplementary conditions which apply when motor reactors are used......................................... 130 1.10.2 dv/dt filters plus VPL and dv/dt filters compact plus VPL ................................................................... 131 1.10.3 Sine-wave filters ................................................................................................................................ 134 1.10.4 Comparison of the properties of the motor-side reactors and filters .................................................. 136

1.11 Motor-side transformers.................................................................................................................................... 138 1.11.1 High low high drives.................................................................................................................. 138

1.12 Load duty cycles............................................................................................................................................... 144 1.12.1 General .............................................................................................................................................. 144 1.12.2 Standard load duty cycles.................................................................................................................. 144 1.12.3 Free load duty cycles......................................................................................................................... 145 1.12.4 Thermal monitoring of the power unit ................................................................................................ 148 1.12.5 Operation of converters at increased pulse frequency....................................................................... 148



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1.13 Power cycling capability of IGBT modules and inverter power units ................................................................ 152 1.13.1 General ............................................................................................................................................. 152 1.13.2 IGBT module with cyclical alternating current load............................................................................ 152 1.13.3 Dimensioning of the power units for operation at low output frequencies.......................................... 153

1.14 Efficiency of SINAMICS converters at full load and at partial load ................................................................... 157 1.14.1 Converter efficiency at full load ......................................................................................................... 157 1.14.2 Converter efficiency at partial load .................................................................................................... 158 1.14.2.1 Description of the calculation method........................................................................................... 158 1.14.2.2 Partial load efficiency of S120 Basic Line Modules ...................................................................... 160 1.14.2.3 Partial load efficiency of S120 Smart Line Modules...................................................................... 162 1.14.2.4 Partial load efficiency of S120 Active Line Modules + Active Interface Modules .......................... 164 1.14.2.5 Partial load efficiency of S120 Motor Modules.............................................................................. 167 1.14.2.6 Partial load efficiency of G130 / G150 converters and S120 Power Modules............................... 170 1.14.2.7 Partial load efficiency of S150 converters..................................................................................... 176 1.14.2.8 Inclusion of motor reactor and motor filter power losses .............................................................. 182

1.15 Parallel connections of converters ................................................................................................................... 183 1.15.1 General ............................................................................................................................................. 183 1.15.2 Parallel connections of SINAMICS converters .................................................................................. 183 1.15.3 Parallel connection of S120 Basic Line Modules............................................................................... 185 1.15.4 Parallel connection of S120 Smart Line Modules .............................................................................. 187 1.15.5 Parallel connection of S120 Active Line Modules.............................................................................. 189 1.15.6 Parallel connection of S120 Motor Modules ...................................................................................... 189 1.15.7 Admissible and inadmissible winding systems for parallel connections of converters....................... 191

1.16 SINAMICS S120 Liquid-Cooled units in Chassis format .................................................................................. 194 1.16.1 General ............................................................................................................................................. 194 1.16.2 Design of the SINAMICS S120 Liquid-Cooled units .......................................................................... 194 1.16.3 Requirements concerning coolant and cooling circuit ....................................................................... 195

2 EMC Installation Guideline ................................................................................................................ 199 2.1 Introduction ........................................................................................................................................................ 199

2.1.1 General ............................................................................................................................................. 199 2.1.2 EC Directives..................................................................................................................................... 199 2.1.3 CE marking........................................................................................................................................ 199 2.1.4 EMC Directive ................................................................................................................................... 200 2.1.5 EMC product standard EN 61800-3 .................................................................................................. 200

2.2 Fundamental principles of EMC ......................................................................................................................... 202 2.2.1 Definition of EMC .............................................................................................................................. 202 2.2.2 Interference emissions and interference immunity ............................................................................ 203

2.3 The frequency converter and its EMC................................................................................................................ 203 2.3.1 The frequency converter as a source of interference ........................................................................ 203 2.3.2 The frequency converter as a high-frequency source of interference................................................ 204 2.3.3 The frequency converter as a low-frequency source of interference ................................................. 208 2.3.4 The frequency converter as potentially susceptible equipment ......................................................... 209 2.3.4.1 Methods of influence ......................................................................................................................... 209 2.3.4.1.1 Conductive coupling ..................................................................................................................... 209 2.3.4.1.2 Capacitive coupling ...................................................................................................................... 210 2.3.4.1.3 Inductive coupling......................................................................................................................... 211 2.3.4.1.4 Electromagnetic coupling (radiative coupling) .............................................................................. 212

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2.4 EMC-compliant installation ................................................................................................................................. 212 2.4.1 Zone concept within the converter cabinet ........................................................................................ 213 2.4.2 Converter cabinet structure ............................................................................................................... 214 2.4.3 Cables inside the converter cabinet................................................................................................... 214 2.4.4 Cables outside the converter cabinet................................................................................................. 215 2.4.5 Cable shields ..................................................................................................................................... 215 2.4.6 Equipotential bonding in the converter cabinet, in the drive system, and in the plant ........................ 215 2.4.7 Examples for installation.................................................................................................................... 217 2.4.7.1 EMC-compliant installation of a SINAMICS G150 converter cabinet unit .......................................... 217 2.4.7.2 EMC-compliant construction/installation of a cabinet with a SINAMICS G130 Chassis unit.............. 218 2.4.7.3 EMC-compliant cable routing on the plant side on cable racks and in cable ducts............................ 219

3 General Engineering Information for SINAMICS............................................................................. 220 3.1 Overview of documentation ................................................................................................................................ 220 3.2 Safety-integrated / Drive-integrated safety functions .......................................................................................... 225

3.2.1 Safe Torque Off (previously known as Safe Standstill) and Safe Stop 1......................................... 225 3.3 Precharging intervals of the DC link ................................................................................................................... 229

3.3.1 SINAMICS Booksize units ................................................................................................................. 229 3.3.2 SINAMICS Chassis units ................................................................................................................... 229

3.4 Operator Panel ................................................................................................................................................... 229 3.4.1 Basic Operator Panel (BOP20).......................................................................................................... 229 3.4.2 Advanced Operator Panel (AOP30)................................................................................................... 229

3.5 CompactFlash Cards for CU320-2 Control Units................................................................................................ 231 3.6 Cabinet design and air conditioning.................................................................................................................... 232

3.6.1 Directives and standards ................................................................................................................... 232 3.6.2 Physical fundamental principles......................................................................................................... 233 3.6.3 Cooling air requirements and air opening cross-sections in the cabinet ............................................ 235 3.6.4 Required ventilation clearances......................................................................................................... 237 3.6.5 Required partitioning.......................................................................................................................... 239

3.7 Changing the power block on power units in Chassis format ............................................................................. 240 3.8 Replacement of SIMOVERT P and SIMOVERT A converter ranges by SINAMICS........................................... 241

3.8.1 General .............................................................................................................................................. 241 3.8.2 Replacement of converters in SIMOVERT P 6SE35/36 and 6SC36/37 ranges by SINAMICS.......... 241 3.8.3 Replacement of converters in SIMOVERT A range by SINAMICS.................................................... 243

4 Converter Chassis Units SINAMICS G130 ....................................................................................... 245 4.1 General information ............................................................................................................................................ 245 4.2 Rated data of converters for drives with low demands on control performance.................................................. 248 4.3 Connection diagramm of the Power Module....................................................................................................... 254 4.4 Incorporating different loads into the 24 V supply............................................................................................... 255 4.5 Factory settings (defaults) of customer interface on SINAMICS G130 ............................................................... 256 4.6 Cable cross-sections and connections on SINAMICS G130 Chassis Units ....................................................... 261 4.7 Precharging of the DC link and precharging currents ......................................................................................... 261 4.8 Line-side components ........................................................................................................................................ 263

4.8.1 Line fuses .......................................................................................................................................... 263 4.8.2 Line reactors ...................................................................................................................................... 263 4.8.3 Line Harmonics Filters ....................................................................................................................... 264 4.8.4 Line filters .......................................................................................................................................... 264



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4.9 Components at the DC link ................................................................................................................................ 265 4.9.1 Braking units...................................................................................................................................... 265

4.10 Load-side components and cables................................................................................................................... 269 4.10.1 Motor reactors ................................................................................................................................... 269 4.10.2 dv/dt filters plus VPL.......................................................................................................................... 269 4.10.3 Sine-wave filters ................................................................................................................................ 269 4.10.4 Maximum connectable motor cable lengths ...................................................................................... 269

5 Converter Cabinet Units SINAMICS G150........................................................................................ 271 5.1 General information............................................................................................................................................ 271 5.2 Rated data of converters for drives with low demands on control performance ................................................. 271 5.3 Factory settings (defaults) of customer interface on SINAMICS G150 with TM31 ............................................. 278 5.4 Cable cross-sections and connections on SINAMICS G150 Cabinet Units........................................................ 280

5.4.1 Recommended and max. possible cable cross-sections for line and motor connections .................. 280 5.4.2 Required cable cross-sections for line and motor connections.......................................................... 282 5.4.3 Grounding and PE conductor cross-section ...................................................................................... 283

5.5 Precharging of the DC link and precharging currents......................................................................................... 284 5.6 Line-side components ........................................................................................................................................ 286

5.6.1 Line fuses .......................................................................................................................................... 286 5.6.2 Line reactors...................................................................................................................................... 286 5.6.3 Line Harmonics Filters....................................................................................................................... 287 5.6.4 Line filters .......................................................................................................................................... 287

5.7 Components at the DC link ................................................................................................................................ 288 5.7.1 Braking units...................................................................................................................................... 288

5.8 Load-side components and cables..................................................................................................................... 291 5.8.1 Motor reactors ................................................................................................................................... 291 5.8.2 dv/dt filters plus VPL.......................................................................................................................... 292 5.8.3 Sine-wave filters ................................................................................................................................ 292 5.8.4 Maximum connectable motor cable lengths ...................................................................................... 292

5.9 SINAMICS G150 parallel converters (SINAMICS G150 power extension)......................................................... 293 5.9.1 6-pulse operation of SINAMICS G150 parallel converters ................................................................ 295 5.9.2 12-pulse operation of SINAMICS G150 parallel converters .............................................................. 296 5.9.3 Operation at motors with electrically isolated and with common winding systems ............................ 297 5.9.4 Special features to note when precharging SINAMICS G150 parallel converters ............................. 298 5.9.5 Overview of SINAMICS G150 parallel converters ............................................................................. 299

6 General Information about Built-in and Cabinet Units SINAMICS S120 ....................................... 300 6.1 General .............................................................................................................................................................. 300

6.1.1 Assignment table............................................................................................................................... 300 6.2 Control properties............................................................................................................................................... 300

6.2.1 Performance features of the CU320-2 Control Unit........................................................................... 300 6.2.2 Control properties / definitions........................................................................................................... 302 6.2.3 Control properties of the CU320-2 Control Unit................................................................................. 303 6.2.4 Determination of the required control performance of the CU320-2 Control Unit .............................. 309

6.3 Rated data, permissible output currents, maximum output frequencies............................................................. 312 6.3.1 Permissible output currents and maximum output frequencies ......................................................... 312 6.3.2 Ambient temperatures > 40C and installation altitudes > 2000 m.................................................... 313

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6.4 DRIVE-CLiQ ....................................................................................................................................................... 315 6.4.1 Basic information ............................................................................................................................... 315 6.4.2 Determination of component cabeling ............................................................................................... 316 6.4.3 DRIVE-CLiQ cables supplied with the units....................................................................................... 317 6.4.4 Cable installation ............................................................................................................................... 318

6.5 Precharging of the DC link and precharging currents .......................................................................................... 321 6.5.1 Basic Infeed....................................................................................................................................... 321 6.5.2 Smart Infeed ...................................................................................................................................... 322 6.5.3 Active Infeed...................................................................................................................................... 323

6.6 Checking the maximum DC link capacitance....................................................................................................... 325 6.6.1 Basic information ............................................................................................................................... 325 6.6.2 Capacitance values ........................................................................................................................... 326

6.7 Connection of Motor Modules to a common DC busbar ..................................................................................... 330 6.7.1 Direct connection to the DC busbar ................................................................................................... 330 6.7.2 Electromechanical connection by means of a switch disconnector.................................................... 331 6.7.3 Electrical connection by means of a switch disconnector and a contactor assambly......................... 331

6.8 Braking Modules / External braking resistors...................................................................................................... 334 6.8.1 Braking Module for power units in Chassis format............................................................................. 334 6.8.2 Braking resistors for power units in Chassis format ........................................................................... 337 6.8.3 SINAMICS S120 Motor Modules as 3-phase Braking Modules ......................................................... 338

6.9 Maximum connectable motor cable lengths........................................................................................................ 343 6.9.1 Booksize units.................................................................................................................................... 343 6.9.2 Chassis units ..................................................................................................................................... 344

6.10 Checking the total cable length for multi-motor drives ...................................................................................... 345 6.10.1 Basic principles.................................................................................................................................. 345 6.10.2 Permissible total cable length for standard conditions ....................................................................... 345 6.10.3 Maximum permissible total cable lengths for any given system-specific conditions .......................... 347

7 General Information about Modular Cabinet Units SINAMICS S120 Cabinet Modules............... 354 7.1 General............................................................................................................................................................... 354

7.1.1 Design ............................................................................................................................................... 354 7.1.2 General configuring process.............................................................................................................. 354

7.2 Dimensioning and selection information ............................................................................................................. 355 7.2.1 Derating data ..................................................................................................................................... 355 7.2.1.1 Derating data for S120 Cabinet Modules with power units in Chassis format.................................... 355 7.2.1.2 Derating data for S120 Cabinet Modules with power units in Booksize format.................................. 356 7.2.2 Degrees of protection of S120 Cabinet Modules ............................................................................... 357 7.2.3 Required cross-sections of DC busbars ............................................................................................ 357 7.2.4 Required cable cross-sections for line and motor connections.......................................................... 358 7.2.5 Cooling air requirements.................................................................................................................... 360 7.2.6 Auxiliary power requirements............................................................................................................. 362 7.2.7 Line reactors ...................................................................................................................................... 369 7.2.8 Parallel configuration ......................................................................................................................... 370 7.2.9 Weights of S120 Cabinet Modules..................................................................................................... 371

7.3 Information about equipment handling ............................................................................................................... 374 7.3.1 Optional customer terminal block -X55 (option G55) ......................................................................... 374 7.3.2 Customer terminal block -X55.1 and -X55.2 ...................................................................................... 376 7.3.3 Auxiliary voltage supply system......................................................................................................... 377 7.3.4 DRIVE-CLiQ wiring ............................................................................................................................ 379



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7.3.5 Erection of cabinets........................................................................................................................... 380 7.3.6 Examples of Cabinet Modules arrangements.................................................................................... 380 7.3.7 Door opening angle ........................................................................................................................... 381

7.4 Line Connection Modules................................................................................................................................... 382 7.4.1 Design ............................................................................................................................................... 382 7.4.2 Planning recommendations, special features.................................................................................... 383 7.4.3 Assignment to the rectifiers / Line Modules ....................................................................................... 383 7.4.4 Parallel connections .......................................................................................................................... 384 7.4.5 DC busbar ......................................................................................................................................... 385 7.4.6 Circuit breakers ................................................................................................................................. 385 7.4.7 Short-circuit strength ......................................................................................................................... 387

7.5 Basic Line Modules ............................................................................................................................................ 388 7.5.1 Design ............................................................................................................................................... 388 7.5.2 DC link fuses ..................................................................................................................................... 389 7.5.3 Parallel connections of Basic Line Modules ...................................................................................... 389

7.6 Smart Line Modules ........................................................................................................................................... 390 7.6.1 Design ............................................................................................................................................... 390 7.6.2 DC link fuses ..................................................................................................................................... 391 7.6.3 Parallel connections of Smart Line Modules...................................................................................... 391

7.7 Active Line Modules + Active Interface Modules ................................................................................................ 392 7.7.1 Design ............................................................................................................................................... 392 7.7.2 DC Link fuses .................................................................................................................................... 394 7.7.3 Parallel connections of Active Line Modules + Active Interface Modules .......................................... 394

7.8 Motor Modules ................................................................................................................................................... 396 7.8.1 Design ............................................................................................................................................... 396 7.8.2 DC link fuses ..................................................................................................................................... 396 7.8.3 Parallel connections of Motor Modules.............................................................................................. 397

7.9 Booksize Base Cabinet / Booksize Cabinet Kits ................................................................................................ 399 7.9.1 Design ............................................................................................................................................... 399 7.9.2 Booksize Base Cabinet ..................................................................................................................... 399 7.9.3 Booksize Cabinet Kits ....................................................................................................................... 399 7.9.4 DC link fuses ..................................................................................................................................... 400 7.9.5 Planning recommendations, special features.................................................................................... 400

7.10 Central Braking Modules .................................................................................................................................. 404 7.10.1 Design ............................................................................................................................................... 404 7.10.2 Position in the DC link configuration.................................................................................................. 406 7.10.3 DC Link fuses .................................................................................................................................... 406 7.10.4 Parallel configuration of Central Braking Modules............................................................................. 406 7.10.5 Braking resistor ................................................................................................................................. 406

7.11 Auxiliary Power Supply Modules ...................................................................................................................... 408 7.11.1 Design ............................................................................................................................................... 408

8 Converter Cabinet Units SINAMICS S150 ........................................................................................ 410 8.1 General information............................................................................................................................................ 410 8.2 Rated data and continuous operation of the converters ..................................................................................... 411 8.3 Factory settings (defaults) of customer interface on SINAMICS S150 with TM31.............................................. 415

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8.4 Cable cross-sections and connections on SINAMICS S150 cabinet units.......................................................... 417 8.4.1 Recommended and max. possible cable cross-sections for line and motor connections .................. 417 8.4.2 Required cable cross-sections for line and motor connections.......................................................... 418 8.4.3 Grounding and PE conductor cross-section ...................................................................................... 419

8.5 Precharging of the DC link and precharging currents ......................................................................................... 419 8.6 Components at the DC link................................................................................................................................. 420

8.6.1 Braking units ...................................................................................................................................... 420 8.7 Load-side components and cables ..................................................................................................................... 421

8.7.1 Motor reactors.................................................................................................................................... 421 8.7.2 dv/dt filters plus VPL .......................................................................................................................... 421 8.7.3 Sine-wave filters ................................................................................................................................ 421 8.7.4 Maximum connectable motor cable lengths....................................................................................... 422

8.8 Option L04 (Infeed Module dimensioned one rating class lower) ....................................................................... 422

9 Description of Options for Cabinet Units......................................................................................... 424 9.1 Option G33 (CBE20 Communication Board) ......................................................................................... 424 9.2 Option K82 (Terminal module for controlling the Safe Torque Off and Safe Stop1 safety functions) 424 9.3 Options K90 (CU320-2 DP Control Unit) and K94 (Performance expansion 1)..................................... 429 9.4 Option L08 (Motor reactor) / L09 (2 motor reactors in series)................................................................ 430 9.5 Option L25 (Circuit breaker in a withdrawable unit design) ................................................................... 430 9.6 Option L34 (Output-side circuit breaker)................................................................................................ 431 9.7 Option L37 (DC interface incl. precharging circuit) ................................................................................ 432 9.8 Option M59 (Closed cabinet doors, air inlet from below through floor openings) .................................. 432 9.9 Option Y11 (Factory assembly into transport units)............................................................................... 433

10 General Information about Drive Dimensioning ........................................................................... 435 10.1 General................................................................................................................................................... 435 10.2 Drives with quadratic load torque ........................................................................................................... 436 10.3 Drives with constant load torque ............................................................................................................ 437 10.4 Permissible motor-converter combinations............................................................................................. 438 10.5 Drives with permanent-magnet three-phase synchronous motors ......................................................... 439

11 Motors................................................................................................................................................ 445 11.1 1LG4 / 1LG6 and 1LA8 self-cooled asynchronous motors ..................................................................... 445 11.2 1PQ8 forced-cooled asynchronous motors ............................................................................................ 445 11.3 1LL8 open-circuit self-cooled asynchronous motors............................................................................... 445 11.4 H-compact PLUS modular asynchronous motors................................................................................... 446 11.5 1PL6 / 1PH7 / 1PH8 compact asynchronous motors.............................................................................. 447 11.6 1FW3 / 1FW4 synchronous motors / high-torque motors with permanent magnets .............................. 447 11.7 Special insulation for line supply voltages > 460 V or 500 V for converter-fed operation ....................... 448 11.8 Bearing currents ..................................................................................................................................... 449 11.9 Motor protection...................................................................................................................................... 449 11.10 Operation of explosion-proof motors with type of protection "d" ........................................................ 449

Fundamental Principles and System Description Engineering Information


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1 Fundamental Principles and System Description

1.1 Operating principle of SINAMICS converters

1.1.1 General operating principle The converters in the SINAMICS product range are PWM converters with a voltage-source DC link. At the input side, the converter consists of a rectifier (shown in the schematic sketch as a thyristor rectifier) which is supplied with a constant voltage VLine and a constant frequency fLine from a three-phase supply. The rectifier produces a constant DC voltage VDCLink, i.e. the DC link voltage, which is smoothed by the DC link capacitors. The IGBT inverter on the output side converts the DC link voltage to a three-phase system with a variable voltage VMotor and variable frequency fMotor. This process operates according to the principle of pulse-width modulation PWM. By varying the voltage and the frequency, it is possible to vary the speed of the connected three-phase motor continuously and virtually without losses.

Block diagram of a PWM converter with voltage-source DC link

1.1.2 Pulse modulation method The power semiconductors of the IGBT inverter (IGBT = Insulated Gate Bipolar Transistor) are high-speed, electronic switches which connect the converter outputs to the positive or negative pole of the DC link voltage. The duration of the gating signals in the individual inverter phases and the magnitude of the DC link voltage thus clearly determine the output voltage and therefore also the voltage at the connected motor.




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If we consider all three phases, there is a total of 2 = 8 switching states in the inverter, and the effect of these states in the motor can be defined by voltage phasors.

Switching states of the inverter Phase L1 Phase L2 Phase L3

V1 + - - V2 + + - V3 - + - V4 - + + V5 - - + V6 + - + V7 + + + V8 - - -

If, for example, phase L1 is connected to the positive DC link voltage, and phases L2 and L3 to the negative voltage so as to produce switching state V1, the resultant voltage phasor points in the direction of motor phase L1 and is designated phase I. The length of this phasor is determined by the DC link voltage.

Representation of resultant motor voltages as phasor If the switching state changes from V1 to V2, then the voltage phasor rotates clockwise by an angle of 60el. due to the change in potential at terminal L2. The length of the phasor remains unchanged. In the same way, the relevant voltage phasors are produced by switching combinations V3 to V6. Switching combinations V7 and V8 produce the same potential at all motor terminals. These two combinations therefore produce voltage phasors of "zero" length (zero voltage phasor).

1.1.2.1 Generation of a variable voltage by pulse-width modulation Voltage and frequency must be specified in a suitable way for a certain operating state of the motor, characterized by speed and torque. Ideally, this corresponds to control of the voltage vector V(t) on a circular path with the speed of rotation t = 2 * * f and adjusted absolute value. This is achieved through modulation of the actual settable voltage space vectors (pulse-width modulation). In this way, the momentary value V(t) is formed by pulses of the adjacent, actual settable voltage space vectors and the voltage zero. The solid angle is set directly by varying the ratio of the ON durations (pulse-width) of adjacent voltage vectors, the desired absolute value by varying the ON duration of the zero voltage vector. This method of generating gating signals is called space vector modulation SVM. Space vector modulation provides sine-modulated pulse patterns.



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The following diagram illustrates how the voltages in phases L1 and L2 plus output voltage VL1-L2 (phase-to-phase voltage) are produced by pulse-width modulation or space vector modulation and shows their basic time characteristics. The frequency with which the IGBTs in the inverter phases are switched on and off is referred to as the pulse frequency or clock frequency of the inverter.

Timing of the gating signal sequence for the IGBTs in the inverter phases L1 and L2 plus the associated output voltage (phase-to-phase voltage) VL1-L2. The amplitude of the voltage pulses corresponds to the DC link voltage. The diagram below shows the time characteristic (in blue) of one of the three output voltages of the inverter (phase-to-phase voltage) and the resulting current (in black) generated in one of the three motor phases when a standard asynchronous motor with a rated frequency of 50 Hz or 60 Hz is used and the inverter is operating with a pulse frequency of 1.25 kHz. The diagram shows that the smoothing effect of the motor inductances causes the motor current to be virtually sinusoidal, despite the fact that the motor is supplied with a square-wave pulse pattern.

Motor voltage (phase-to-phase) and motor current with space vector modulation




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1.1.2.2 Maximum attainable output voltage with space vector modulation SVM Space vector modulation SVM generates pulse patterns which approximate an ideal sinusoidal motor voltage through voltage pulses with constant amplitude and corresponding pulse-duty factor. The peak value of the maximum (fundamental) voltage that can be attained in this way corresponds to the amplitude of the DC link voltage VDCLink. Thus the theoretical maximum motor voltage with space vector modulation which results is:

DCLinkSVM VV = 21

max

The amplitude of the DC link voltage VDCLink is determined by the method of line voltage rectification. With line-commutated rectifiers used with SINAMICS G130 and G150 and also with S120 Basic Line Modules, it averages 1.41*VLine with no load, 1.35*VLine with partial load and 1.32*VLine.with full load. Thus with the true DC link voltage amplitude of VDCLink 1.32*VLine at full load, the motor voltage theoretically attainable at full load with space vector modulation without overmodulation is: VSVM max = 0.935 * VLine . As a result of voltage drops in the converter and minimum pulse times and interlock times in the gating unit responsible for generating the IGBT gating pulse pattern, the values in reality are lower. In practice, therefore, the value for space vector modulation without overmodulation must be assumed to be as follows: VSVM max 0.92 * VLine This value applies precisely to pulse frequencies of 2.0 kHz or 1.25 kHz according to the factory setting. At higher pulse frequencies, it decreases by approximately 0.5 % per kHz.

1.1.2.3 Maximum attainable output voltage with pulse-edge modulation PEM It is possible to increase the inverter output voltage above the values attained with space vector modulation (SVM) by pulsing only at the edges of the fundamental-wave period rather than over the entire fundamental-wave period. This process is referred to as pulse-edge modulation (PEM). The basic waveform of the motor voltage is then as shown below.

Motor voltage with pulse-edge modulation PEM

The maximum possible output voltage is attained when clocking is performed with the fundamental frequency only, i.e. when "pulsing" ceases altogether. The output voltage then consists of 120 rectangular blocks with the amplitude of the DC link voltage. The fundamental frequency RMS value of the output voltage can then be calculated as:

LineLineDCLinkrect VVVV === 03.132.166

So it is possible with pure rectangular modulation to achieve a motor voltage which is slightly higher than the line voltage. However, the motor voltage then has an unsuitable harmonic spectrum which causes major stray losses in the motor and utilizes the motor inefficiently. It is for this reason that pure square-wave modulation is not utilized on SINAMICS converters. The pulse-edge modulation method used on SINAMICS converters permits a maximum output voltage which is only slightly lower than the line voltage, even when allowance is made for voltage drops in the converter: VPEM max 0.97 * VLine The pulse-edge modulation process uses optimized pulse patterns which cause only minor harmonic currents and therefore utilize the connected motor very efficiently. Commercially available standard asynchronous motors for 50 Hz or 60 Hz and utilized according to temperature class 130 (B) in mains operation can be partially utilized according to temperature class 155 (F) at the nominal working point up to rated torque when operated with pulse-edge modulation.



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Pulse-edge modulation is available as standard in vector control mode (drive object of vector type) on all SINAMICS units described in this engineering manual:

SINAMICS G130* Chassis SINAMICS G150* Cabinets SINAMICS S150* Cabinets SINAMICS S120* Motor Modules / Chassis format SINAMICS S120* Motor Modules / Cabinet Modules format

The factory setting of parameter P1802 (modulator mode) is "9" (pulse-edge modulation) for SINAMICS G130 and G150 converters which are employed predominantly in combination with asynchronous motors without speed encoder for applications with low dynamic requirements. At a low output frequency and low depth of modulation (output voltage < 92 % of input voltage), these products utilize space vector modulation SVM and switch over to pulse-edge modulation PEM automatically if the depth of modulation required at higher output frequencies is so high that it can no longer be provided by space vector modulation (output voltage > 92 % of input voltage). The minor irregularities in the torque characteristic curve caused by transient phenomena during transition between modulation systems are virtually irrelevant for applications with simple control requirements.

The factory setting for parameter P1802 (modulator mode) in vector control mode is "4" (space vector modulation without overmodulation) for SINAMICS S120 Motor Modules and SINAMICS S150 converters. These units utilize only space vector modulation SVM in the factory setting because, and this applies particularly to SINAMICS S120 Motor Modules, they are predominantly employed in coordinated multi-motor systems which demand very high control quality (e.g. paper-making machinery). These types of application with exacting control standards can rarely tolerate the minor irregularities in the torque characteristic curve caused by transient phenomena during transition between modulation systems. If SINAMICS S120 Motor Modules and SINAMICS S150 converters are required to operate with pulse-edge modulation PEM, parameter p1802 (modulator mode) must be set to "9" (pulse-edge modulation) during commissioning.

In principle, it would also be possible to achieve depths of modulation or output voltages in excess of 92 % through overmodulation of the space vector modulation SVM (by setting parameter p1802 to values between 0 and 2). While it is possible by this method to prevent the slight irregularities in the torque characteristic curve on transition between modulation systems, it also causes the harmonics spectrum in the motor current to increase, resulting in higher torque ripples and a significant rise in motor losses. Here, therefore, pulse-edge modulation PEM with its optimized pulse patterns offers obvious advantages, as it enables a high depth of modulation (high output voltage) combined with good drive behavior (in terms of torque accuracy and motor losses) to be achieved. * Exceptions regarding the use of pulse-edge modulation:

Converters with output-side sine-wave filter. Pulse-edge modulation cannot be selected under these conditions.

If either a Basic or Smart Infeed is used to supply the inverter, the following formulae apply for the DC link voltage at full load: VDCLink 1.32 VLine resp. VDCLink = 1.30 VLine. In this case, the maximum output voltage is limited to 85 % of the line input voltage for units with a supply voltage of 380 V to 480 V 3AC and to 83 % for units with a supply voltage of 500 V to 600 V 3AC.

If an Active Infeed is used to supply the inverter, the following formula applies to the DC link voltage because the Active Infeed utilizes a step-up converter function: VDCLink > 1.42 VLine (factory setting: VDCLink = 1.5 VLine). This means that the maximum output voltage even without pulse-edge modulation can correspond to 100 % of the line input voltage or higher if the parameters of ratio VDCLink / VLine are set to sufficiently high values on the Active Infeed. This is described in the section SINAMICS Infeeds and their properties, subsection Active Infeeds. Note:

Pulse-edge modulation PEM is available only in vector and V/f control modes (drive objects of vector type) and is generally utilized on drives with asynchronous motors. In servo control mode (drive objects of servo type), converters always operate with space vector modulation SVM with automatic overmodulation. The reason for this is the slower dynamic response of the drive in operation with pulse-width modulation. This is acceptable for many applications with vector control, but not for highly dynamic applications with servo control.




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1.1.3 The pulse frequency and its influence on key system properties The pulse frequency of the inverter is an important parameter which has a crucial influence on various properties of the drive system. It can be varied within certain given limits. In order to reduce the motor noise, reach very high output frequencies or in the event that sinus filters are to be used at the converter output, it is sensible, or rather necessary, to increase the pulse frequency.

The following aspects of the pulse frequency are described briefly below: The pulse frequency factory settings The limits within which the pulse frequency can be adjusted The effect of the pulse frequency on various properties of the drive system When it is advisable or even essential to change the pulse frequency What needs to be noted in connection with motor-side options (motor reactor, motor filter).

Factory settings and pulse frequency setting ranges The pulse frequency of the motor-side inverter on SINAMICS G130, G150, S150, S120 (Chassis and Cabinet Modules) operating in vector control mode (drive object of vector type) is preset at the factory to 2.0 kHz or 1.25 kHz as specified in the table below.

Line supply voltage Power Rated output current Pulse frequency factory setting

380 V to 480 V 3AC 250 kW 490 A 2.00 kHz 315 kW 605 A 1.25 kHz 500 V to 600 V 3AC All power ratings All currents 1.25 kHz 660 V to 690 V 3AC All power ratings All currents 1.25 kHz

Converter-dependent factory setting of pulse frequency for SINAMICS G130, G150, S150 and for SINAMICS S120 Motor Modules, Chassis and Cabinet Modules

The pulse frequency can be varied in discrete steps. Possible settings correspond to twice the factory setting value in each case as well as whole multiples thereof. Depending on the unit type, the pulse frequency can therefore be increased to 8 kHz (when factory setting is 2 kHz) or to 7.5 kHz (when factory setting is 1.25 kHz). In vector control mode (drive object of vector type) switching between integer multiples of the pulse frequency is also possible when the drive is in operation, i.e. by means of a parameter change or data set changeover. By changing the current controller clock cycle, it is also possible to set intermediate values, so that the pulse frequency can adjusted in fine increments. Intermediate values can be set only when the drive is at standstill.

Influence of the pulse frequency on the inverter output current The pulse frequency factory setting of either 2.0 kHz or 1.25 kHz is relatively low in order to reduce inverter switching losses. If the pulse frequency is increased the inverter switching losses and thus also the total losses in the converter increase accordingly. The result would be overheating of the power unit when operating at full load capacity. For this reason, the conducting losses must be lowered in order to compensate for the increase in switching losses. This can be achieved by reducing the permissible output current (current derating). The current derating factors as a function of pulse frequency are unit-specific values and must be taken into account when the converter is dimensioned. The derating factors for various pulse frequencies can be found in the chapters on specific unit types. If derating factors are required for pulse frequencies which are not included in the tables, they can be calculated by linear interpolation between the stated table values. Under certain boundary conditions (line voltage at low end of permissible wide-voltage range, low ambient temperature, restricted speed range), it is possible to partially or completely avoid current derating at pulse frequencies which are twice as high as the factory setting. For further information, please refer to section "Operation of converters at increased pulse frequency".

Influence of the pulse frequency on losses and efficiency of inverter and motor With the factory set pulse frequency of 2.0 kHz or 1.25 kHz, the motor current is already close to sinusoidal. The stray losses in the motor caused by harmonic currents are low, but not negligible. Commercially available standard motors for 50 Hz or 60 Hz and utilized according to temperature class 130 (B) in mains operation can be partially utilized according to temperature class 155 (F) at the nominal working point up to rated torque when operated on a converter. The winding temperature rise is then between 80 and 100 K. Raising the pulse frequency on standard motors for 50 Hz or 60 Hz reduces the motor stray losses only slightly, but results in a considerable increase in the converter switching losses. The efficiency of the overall system (converter and motor) deteriorates as a result.



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Influence of the pulse frequency on motor noise A higher level of magnetic motor noise is excited when three-phase motors are operated on PWM converters. This is caused by the voltage pulsing which results in additional voltage and current harmonics. According to IEC/TS 60034-17 "Rotating electrical Machines Part 17: Cage asynchronous motors when fed from converters - Application guide, the A-graded noise pressure level increases in the order of magnitude of between 1 dB and 15 dB when three-phase motors are operated on a PWM converter up to rated frequency as compared to motors of the same type operating on sinusoidal voltage at rated frequency. The actual values depend on the PWM method used, the pulse frequency of the converter and the design and number of poles of the motor. In the case of SINAMICS converters operating in vector control mode (drive object of vector type) at the factory-set pulse frequency, the additional noise pressure level produced by the motor as a result of the converter supply is typically in the order of magnitude of between 5 dB(A) and maximum 10 dB(A). Converters with a pulse frequency of 2 kHz tend to produce noise pressure in the lower range, those with a pulse frequency of 1.25 kHz in the upper range. Extreme values of up to 15 db(A) can occasionally be reached where peripheral conditions are less favorable (e.g. when mechanical resonance is excited).

Reduction in motor noise through increase in pulse frequency A reduction of the additional motor noise caused by the converter supply can generally be achieved by an increase in the pulse frequency. It can therefore be meaningful to raise the pulse frequency in order to attenuate the motor noise. It must be noted that inverter current derating might be necessary at higher pulse frequencies. Under certain boundary conditions (line voltage at low end of permissible wide-voltage range, low ambient temperature, restricted speed range), it is possible to partially or completely avoid current derating at pulse frequencies which are twice as high as the factory setting. For further information, please refer to section "Operation of converters at increased pulse frequency". Increasing the pulse frequency not only necessitates current derating, but might also impose limits on other motor-side options, such as motor reactors, dv/dt filters and sine-wave filters.

Reduction in motor noise through load-dependent pulse frequency switchover If current derating and associated overdimensioning of the converter which are necessitated by a continuously increase in the pulse frequency are not acceptable for economic reasons, an alternative option in vector control mode (drive object of vector type) is to switch over pulse frequencies as a function of load or speed while the converter is running. This measure is especially effective for pump and fan drives with a square-law speed/torque characteristic. In this case, the converter can operate at a higher pulse frequency in the partial-load range. When the load or speed reaches a limit that is individually defined for each drive, the pulse frequency factory setting is reactivated again in response to a data set switchover. In this way, the motor noise can be reduced to a lower level over most of the speed setting range. The motor noise increases only in the rated load range, which normally represents only a small percentage of the overall operation time of the drive.

Reduction in motor noise through flux decrease (efficiency optimization) The factory settings of SINAMICS converters are devised such that they can operate motors at rated flux over the entire base speed range up to rated speed. This setting is essential for constant-torque drives. In the case of pump and fan drives with a square-law speed/torque characteristic, however, it is generally possible to reduce the motor flux in the partial-load range. In addition to reducing the losses in the converter and motor, decreasing the flux is generally also effective in attenuating the additional motor noise caused by the converter. The flux setting is a parameterizable quantity (P1580).

Reduction in motor noise through pulse frequency wobbling So-called "pulse frequency wobbling" can be activated via parameter p1810 for Chassis and Cabinet units (not possible on earlier units with CIB module and CU320 Control Unit with firmware versions < 2.6). This has the effect of slightly varying the pulse frequency according to a statistical process. The mean pulse frequency equals the set value as before, but the noise spectrum is modified by the statistical variation in the instantaneous value. As a result, the subjectively discernible motor noise decreases, especially at the relatively low factory-set pulse frequencies. For further details about parameter assignments, please refer to the function manual "SINAMICS S120 Drive Functions" and the list manuals.

Note: Pulse frequency wobbling can be activated only on power units in Chassis format. Pulse frequency wobbling can be activated for single units only, but not for parallel connections. Pulse frequency wobbling is possible only in the vector and V/f control modes, but not in servo control mode. Active pulse frequency wobbling is not compatible with pulse-edge modulation. The maximum pulse frequency fp-max with wobbling equals fp-max = 1/current controller sampling time, i.e.:

fp-max = 4 kHz with current controller sampling time 250 s and fp-max = 2.5 kHz with current controller sampling time 400 s




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Correlation between pulse frequency and converter output frequency (fundamental wave frequency) With space vector modulation, there is a fixed correlation between the pulse frequency and the maximum attainable converter output frequency (fundamental wave frequency). The pulse frequency must be at least 12.5 times higher than the required converter output frequency on SINAMICS converters. This means that the maximum achievable output frequency at a given pulse frequency is limited according to the formula fConverter max = fpulse / 12.5 (but a maximum of 300 Hz on asynchronous machines with vector control mode).

The table below shows the possible pulse frequency settings and the associated maximum achievable output frequencies for converters and inverters with the factory-set current controller clock cycles and pulse frequencies fpulse = 2.0 kHz or fpulse = 1.25 kHz. The current controller clock cycle can be varied to set intermediate values, allowing higher output frequencies (values on request) than specified in the table to be achieved under certain boundary conditions.

Units with factory setting fpulse = 2.0 kHz Units with factory setting fpulse = 1.25 kHz Pulse frequency Max. output frequency Pulse frequency Max. output frequency 2.0 kHz 160 Hz 1.25 kHz 100 Hz 4.0 kHz 300 Hz 2.50 kHz 200 Hz 8.0 kHz 300 Hz 5.00 kHz 300 Hz - - 7.50 kHz 300 Hz

Settable pulse frequencies and associated maximum attainable output frequencies on SINAMICS converters

Correlation between pulse frequency

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